MONOLITHIC CONVERTER(w/ DPF) INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Set a new gasket and the exhaust manifold converter sub-assembly to the turbocharger sub-assembly.

    2. Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the 3 bolts.

    3. B002679C01
      *1 Exhaust Pipe Clamp
      *2 Exhaust Manifold Converter
      *3 Turbocharger Sub-assembly
      *4 Gasket

      Install a new exhaust pipe clamp to the exhaust manifold converter sub-assembly with a new nut.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  2. INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY


    1. Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the bolt and 2 new nuts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  3. INSTALL NO. 1 TURBO INSULATOR


    1. Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  5. INSTALL AIR FUEL RATIO SENSOR

    Click here

  6. INSTALL UPPER ARM BUSH HEAT INSULATOR


    1. Install the upper arm bush heat insulator to the body with the 2 bolts.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  7. INSTALL NO. 2 INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD)

    Click here

  8. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Attach the 2 clamps and connect the engine wire to the cylinder head sub-assembly.

  9. INSTALL PIPE CLAMP


    1. Install the pipe clamp to the engine cover bracket with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  10. TEMPORARILY INSTALL NO. 2 VACUUM PIPE


    1. Install a new clamp to the pipe clamp.

    2. Temporarily install the No. 2 vacuum pipe to the exhaust manifold converter sub-assembly.

  11. TEMPORARILY INSTALL NO. 1 VACUUM PIPE


    1. Temporarily install the No. 1 vacuum pipe to the exhaust manifold converter sub-assembly.

    2. Install a new clamp to the No. 1 vacuum pipe and No. 2 vacuum pipe with the nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  12. TIGHTEN NO. 2 VACUUM PIPE


    1. B0068F6C01
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the No. 2 vacuum pipe.

      Torque:
      Specified tightening torque
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 42.9 N*m (437 kgf*cm, 32 ft.*lbf)

  13. TIGHTEN NO. 1 VACUUM PIPE


    1. B0068F6C01
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the No. 1 vacuum pipe.

      Torque:
      Specified tightening torque
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 42.9 N*m (437 kgf*cm, 32 ft.*lbf)

  14. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Click here

  15. INSTALL DIFFERENTIAL PRESSURE SENSOR

    Click here

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  18. INSTALL AIR CLEANER CAP AND HOSE

    Click here

  19. INSTALL FRONT FENDER SEAL


    1. for 2WD:

      Install the front fender seal to the body with 5 new clips.

    2. for 4WD and Pre-Runner:

      Install the front fender seal to the body with 6 new clips.

  20. INSTALL FUEL ADDITION INJECTOR ASSEMBLY

    Click here

  21. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  22. BLEED AIR FROM FUEL SYSTEM

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  23. ADD ENGINE COOLANT

    Click here

  24. INSPECT FOR COOLANT LEAK

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